Shingle counting device



Feb. 23, 1943. w ADAMS SHINGLE COUNTING DEVICE Fil ed Sept. 8, 1941 2Sheets-Sheet 1 FLOYD MAD/1M5 w. ATTORNE 5.

Feb. 23, 1943. F. w. ADAMS SHINGLE counnne DEVICE Fi'le d Sept. 8, 19412 Sheets-Sheet 2 INVENTOR ATTORNE 5,

Patented Feb. 23, 1943 I SHINGLE COUNTING DEVICE Floyd W. Adams, SouthGate CaliL, asslgnor tov United States Gypsum Company, Chicago, Ill,

a corporation of Illinois Application September a, 1941, Serial no;410,007

10 Claims.

This invention relates to counting devices for articles of manufacture,and more particularly to counting devices adapted for counting asphaltshingles or the like delivered from a conveyor to a pickup rack.

In forming bundles of the asphalt shingles as delivered from a cuttingmachine, it is customary to manually assemble the shingles so that, atleast in the lighter weight typesof shingles, each bundle or a group oftwo or more bundles may contain a predetermined number of shinglessuflicient to cover a square of surface. That is, one bundle, or ifdesired a group of bundles, will cover 100 square feet of surface whenthe shingles are laid in the required manner. The number of shinglesrequired in a bundle or group to cover a square varies with the type ofshingle and its coverage per shingle.

For some types of shingles, particularly the heavier ones, it isdesirable to have a group of at "least three bundles contain therequired number of shingles to accurately cover a square. In otherwords, if a heavy type of shingle requires eighty shingles to cover asquare, then the shingles may be assembled in consecutive groups ofbundles, the bundles of each group containing 2 6, 27, and 27 shingles,respectively, and preferably, although not necessarily, in thatconsecutive order. Each bundle of a group may, therefore, containsuflicient shingles to cover approximately one-third of a square and thethree bundles of the group will accurately cover one square. 1

In manufacturing these shingles, a web of asphalt material is passedthrough a shingle cutting machine in which the web is first cut into oneor more streams of shingles, each stream the width of one shingle. Withsome types of shingles, three streams are simultaneously cut; the twoouter shingle streams are usually diverted angularly downward and theintermediate stream is directed angularly upward by means of beltconveyors. The shingles are delivered from each conveyor onto respectivepickup racks or "catchers.

The workman or so-called picker who takes the pickups from the racksmust be certain that move the pickups from the catchers when apredetermined number of shingles have been assembled thereon asindicated by a counter signal and, when the usual type of counter isused, he must also add to, or remove from, the bundles one or moreshingles so that each bundle will contain the required number,

When the usual type of automatic shingle counter is used, the counter isset to ring a bell whenever ten shingles have been delivered to a rack.Therefore, when any number of shingles other than a multiple of ten isrequired to form a bundle, the picker finds it necessary to keep a stackof loose shingles at his side and add a few shingles to, or remove a fewfrom, those picked from the catcher in order to produce a bundlecontaining the proper number of shingles. Thus, if a type of shinglerequires 43 shingles to the bundle, the picker would add 3 shingles tothe 40 shingles taken from the catcher in four pickups to make theproper bundle count. If only 39 shingles are required, he would removeone shingle. With such a system, the responsibility for accuracy of thecount is entirely on the picker and many errors are made. The number ofshingles picked from the loose pile often varies with the result thatthe number of shingles in a. bundle is incorrect. Furthermore, theaddition of extra shingles from the loose stack or removal of shinglesfrom the pickups entails considerable extra labor.

It is an object to provide an automatic shingle counter which willaccurately count the varying number of shingles in the separate pickupsof a series as the pickups are consecutively assembled on a catcher, sothat a predetermined number of pickups of the series may form a bundlehaving the correct number of shingles to substantially cover apredetermined area, and also wherein the total number of shingles ineach predetermined number of pickups to form a bundle may be an odd oreven number as required.

It is a further object to provide, in combination with a shinglemachine, a means and method for counting different numbers of shinglesin certain consecutive pickups of a continuous cycle. of groups ofpickups, the number of shingles in the individual pickups of a cyclebeing related so that each group of a predetermined number of pickupshas the same number of shingles therein irrespective of which pickup inthe cycle is first picked up to start the cycle.

It is also an object of the present invention to produce an automaticshingle counter which will accurately count out the correct number ofshingles to a bundle or a group of bundles without manual attention.

Another object of the invention is to produce an automatic shinglecounter which will materially decrease the labor of the picker.

A further object is to produce an automatic counting device havinginterchangeable controls whereby the count for bundles or groups ofbundles may easily and quickly be changed as required. v a

In the drawings:

Fig. 1 is a side elevation of the delivery end of a shingle cuttingmachine with the improved shingle counter operatively associated there'-with.

Fig. 2 is a somewhat diagrammatic elevation of the discharge end of themachine with the catcher plates removed.

Fig. 3 is a fragmentary sectional elevation through the machine taken online 3-3 of Fi 1.

Fig. 4 is a side elevation of the counter mechanism shown in Fig. 3 withthe switch box in section.

Referring to the drawings in detail, the wide web of asphalt shinglematerial l0 passes between a pair. of driven push rolls H and a pair ofcutting cylinders l2 which cut the web into streams of individualshingles. The shingle streams are then separated by suitable inclinedplates l3 so that the central stream of shingles passes upwardly betweendelivery belts i4 and each of the other streams passes downwardlybetween delivery belts l5 (Figs. 1 and 2). The individual shingles fromupper belts id drop onto a catcher comprising a plate or support it havean adjustable angle stop I! thereon for engaging the edge of a stack ofshingles 18. Each stack of a predetermined number of shingles iscommonly called a :pickup. In a similar way the shingles from each setof lowered belts l5 drop onto a respective lower catcher comprising aplate 19 having an angle plate 20 to form a pickup of shingles 2 l Theupper belts i4 pass around driven rolls 22 and 23 which are mounted onshafts 24 and 25, respectively. The above described machine is wellknown to the art.

In the present embodiment the shingle counting device is preferablydriven by the shaft 24. A worm 26 (Fig. 3) is secured to the shaft 24 bymeans of an extension 24a and meshes with a worm wheel 21 secured on oneend of a short transverse shaft 28, the latter being rotatably supportedin a bearing bracket 29. Bearings 3|! support the shaft extension 24aand may also be secured to the bracket 29. A sprocket wheel 32 issecured to the end of shaft 28 opposite the worm wheel 21, and aplurality of timing chains 33, only one of which is shown, are adaptedto be interchangeably suspended from the sprocket wheel 32. Trippinglugs 34 are secured in spaced relation on the links of each chain 33 andthese lugs are arranged, to successively contact a roller 35, whichlatter is rotatably mounted on one end of a switch arm 36, the switcharm being secured to an oscillatable switch shaft 31.

A housing 38 encloses the switch mechanism and provides one or morebearings 39 to oscillatably support the switch shaft 31. A contactor 40is secured to the switch shaft 31 and makes contact with electricalcontact terminals 4| when the roller 35 is moved to the left by one ofthe lugs 34 (Fig. 3). A coil spring 37a around the switch shaft 31serves to open the circuit after the lug 34 passes roller 35. Conductorwires 42 leading from the terminals til connect a standard electric bellor other signal device 43 (Fig. 1) with a source of electrical energy,so that, when the circuit is closed by the actuation of roller 35 by thechain lug 3d, the signaling device will operate, indicating that pickupswith a predetermined number of shingles therein have been delivered tothe catcher plates 55 and ill. The workmen then remove the pickups fromthe catcher plates 56 and i9 and the counting cycle is repeated.

The ratios of the gearing elements 26, 27, and 32 of the counter are soadjusted that, for each shingle delivery to the racks, the chain 33moves the length of one of its links. The contact lugs 34 are spaced onthe chain 33 as many links between them as the predetermined number ofshingles in the respective pickup. A separate chain 33 is provided foreach type of shingle requiring a different count. When changing types ofshingles, the chain 33' with the proper spacing of lugs 35 thereon isselected and substituted on the sprocket 32 for the chain last used.

A predetermined number of pickups, preferably four, taken from thecatcher plates it and B9 are assembled to form a bundle of shingles ofthe desired count. For instance, if a type of shingle requires twobundles with 43 shingles in each bundle to cover a square, a chain of 43links might be used and a series of four lugs spaced apart 10, .ll, 11,and 11 links, respectively. Thus, one complete cycle of this chain wouldcount four pickups, which pickups when assembled form a bundlecontaining the required number of shingles, that is, 43, to exactlycover one half square. The number of shingles is not the same in eachpickup; however, the total is the required number 43.

When shingles of the type just mentioned, wherein more than one bundleis required to cover a square, it is preferable to provide a chainhaving a suificient number of links to count out a complete cycle of twogroups of pickups, each group containing a suihcient number of pickupsto form a bundle and the complete cycle containing a suilicient numberto form two bundles containing the correct number so that, when laid,they will cover a square. The chain for such a cycle would contain 86links and the lugs might be spaced with the following numbers of linksbetween successive lugs in the cycle: 10, 11, 11, 11-10, 11, 11, 11,This arrangement provides a cycle of two groups of four pickups each or43 shingles in each group.

The shaft 24 on which the sprocket 32 is secured rotates in synchronismwith the movement of the shingles so that one link of the chain passesthe switch tripping roller 35 for each shingle delivery to the racks.The chain may contain a sufllcient number of links and switch trippinglugs so that a complete cycle of the chain will count out the correctnumber of pickups for a plurality of bundles, each bundle containing therequired predetermined number of shingles. With some types of shingles,particularly the heavier ones, it is desirable to assemble bundles inconsecutive groups .with three bundles in each group,

so that each group of three bundles will contain suiiicient shingles toexactly cover a square. This also may be accomplished by using a chainin which the number of links used to count the required shingles foreach group of bundles is a multiple of the total number 01! links in thechain.

The following tables indicate the type of chains used in actual practicefo various types of shingles.

Pickp per bundle Bundle counts Chain Total No. oilinks between No.contact lugs ion With the contact lugs spaced on the chains as indicatedin the above table, it is apparent that each bundle and each group ofbundles will contain the required number oi shingles if the pickup isstarted at predetermined points in the cycle.

In order to obviate the necessity for starting the ickups at apredetermined point in the chain cycle and to provide the requirednumber ofshingles in each bundle and, as in types E and F, in

each bundle and in the respective order shown, if desired, irrespectiveof where the pickup cycle is started, the switch tripping lugs may bespaced on the chain as shown in the following table:

No. 0! links between contact lugs Bundle Chain counts No.

Total links 1 43-43.--. 50-50 HHiO 13-14-] 3-13 11-1 1-1 l-111 1-11-11-1 1- 12l1-111l11-11-1l- 11-11-12 assess 4 05 NNi-Ibhb This latterarrangement provides certain material advantages in that, with all typesof shingles, consecutive bundles of a group with different numbers ofshingles in the bundles may always be assembled in a predetermined orderwithout requiring any attention by the workman with respect to thepickup starting point relative to the lug spacing.

The invention insures accurate bundle counts in either individualbundles or groups of bundles and very materially reduces the workrequired of the pickers. In fact, the human element is substantiallyeliminated in so far as accurate count is concerned.

Each chain may be numbered or labeled in accordance with the type 0!shingle with which it; is to be used and the chains are easilyinterchangeable as they are merely removably suspended on a sprocket.

It is intended, or course, that the invention should not be limited tothe specific embodiment or embodiments disclosed herein, sincemodifications may be made, and it is contemplated, therefore, by theappended claims to cover any such modifications as fall within the truespirit and scope of this invention.

Having thus described this invention, when is claimed and desired to besecured by Letters Pattent is:

1. In a shingle machine the combination with means for deliveringconsecutive shingles to a catcher to form pickups of a plurality oishingles, and means movable synchronously with the delivery of saidshingles, of means controlled by said movable means to operate a signalwhen each pickup of a cycle comprising a predetermined number of pickupshas been completed and with one or more or the pickups of each cyclecontaining a predetermined difiei-ent number of shingles than otherpickups oi the same cycle.

2. In a shingle machine'the combination with means ior deliveringconsecutive shingles to a catcher to form pickups of a plurality ofshingles, of a signal, means synchronized with said shingle deliverymeans to cause operation "of said signal when each pickup has beencompleted, said signal operating means being so timed with the deliveryof individual shingles that the number of shingles in predeterminedpickups will be different than in other pickups so that the consecutivepickups as signaled will be in cycles of consecutive groups of pick-upswith the same number of shingles in each group, and with a differentnumber of shingles in at least one pickup of at least one of said groupsthan in the remaining pickups of the same group.

3. In a shingle machine the combination with meansfor deliveringconsecutive shingles to a catcher to form pickups of a plurality ofshingles, of a signal, means synchronized with said shingle deliverymeans to cause operation of said signal when each pickup has beencompleted; said signal operating means being so timed with the deliveryof individual shingles that the number of shingles in predeterminedpickups will be diiierent than in other pickups so that the consecutivepickups as signaled will be in cycles of consecutive groups of pickupswith a diil'erent number of shingles in at least one group than in there- I moving on said sprocket will cause a cycle of signals eachcorresponding to a pickup, and the total corresponding to a cyclecomprising a plurality of groups, all groups consisting of the samenumber of pickups and with one or more pickups of at least one grouphaving a different number of shingles than the other pickups of the samegroup, each group containing a predetermined number of shingles to forma bundle and the complete cycle of groups corresponding to the requirednumber of shingles to form a square.

5. In a counting device for shingles or the like, means for successivelydelivering shingles to be counted, a catcher for said shingles, asprocket wheel driven in synchronism with said shingle delivery means,an endless chain supported on said sprocket wheel, said chain beingrelated to said delivery means so as to move the length of one link foreach shingle delivered, a plurality of spaced contact lugs on saidchain, each adjacent pair of lugs being spaced a multiple of the lengthof a chain link to form a cycle of nonuniiormly spaced lugs, and asignaling device arranged to be actuated periodically by said contactlugs and in accordance with the spacing thereof to inlugs, said lugsbeing spacedon said chain to operate said signals in cyclescorresponding to equal numbersof shingles with signaled groups in eachcycle corresponding to unequal numbers of shingles.

i. In a device for counting shingles, a plurality of catcher supports, aplurality of rotatable means operative to deliver shingles to therespective supports, a sprocket wheel operatively connected to one ofsaid rotatable means, a chain suspended on said sprocket wheel, contactlugs at predetermined unequal intervals on said chain. and a signalingdevice actuated by the movement of said contact lugs to successivelyindicate predetermined unequal numbers of shingles delivered to saidcatcher supports, said lugs being relatively positioned on said chainand related to the delivery means to cause operation of said signaldevice during each complete cycle of said chain to indicate the deliveryof a series of groups of a nonuniform number of shingles in said groups.

8- In a shingle counter, a sprocket or the like rotatable in synchronismwith the consecutive delivery of shingles from a shingle machine, an

endless chain or the like suspended on said sprocket, a signal, aplurality of means spaced on said chain and arranged to intermittentlyoperate said signal for each plurality of discharged shingles forming apickup, said pickups forming consecutive groups, each group containing asufficient number of shingles to form a bundle, a complete chain cyclecorresponding to' a plurality of complete bundles having a total numberof shingles in the cycle of bundles to form a square, the number ofshingles in at least one pickup of at least one group being difierentthan the remaining pickups of the same group, the spacing of saidplurality of signal operating means on said chain being arranged so thatthe respective bundles of a complete cycle will contain the same numberof shingles irrespective of which signal operating means on the chain isused to start the chain cycle with respect to the pickups.

9. In a shingle machine, means for consecutively delivering shingles toa support to form pickup stacks, and means for automatically signalingthe formation of each pickup stack in cycles of constantly recurringgroups of pickups with one or more pickups ineach recurring groupcomprising a different number of shingies than in the-other pickups ofthe same group.

10. In a shingle manufacturing machine the combination with means toconsecutively deliver shingles to form a stack, of automatic means tooperate a'signal in cycles of a plurality of signals, said pluralitycorresponding to the number of groups required to form a bundle with thenumber of groups in a bundle corresponding to a cycle, one or more ofwhich groups comprise a different number of shingles than other groupsin a cycle.

FLOYD w. ADAMS.

